Charge circuitry for an aerosol delivery device

ABSTRACT

An aerosol delivery device is provided that includes a housing structured to retain an aerosol precursor composition, a heating element configured to convert electricity to heat and thereby vaporize components of the aerosol precursor composition, a power source including one or more batteries or battery cells coupled to and configured to power a load including the heating element, and charge circuitry coupled to and configured to controllably charge the power source. The charge circuitry includes an electrical connector configured to connect the charge circuitry to a power supply from which the power source is chargeable, and a buck-boost charge controller coupled to and between the power source and power supply. The buck-boost charge controller is configured to regulate output voltage and output current from the power supply to the power source, selectively in one of a plurality of modes based on a condition of the power supply.

TECHNOLOGICAL FIELD

The present disclosure relates to aerosol delivery devices such aselectronic cigarettes and heat-not-burn cigarettes. The aerosol deliverydevice may be configured to heat an aerosol precursor composition, whichmay be made or derived from tobacco or otherwise incorporate tobacco, toform an inhalable substance for human consumption.

BACKGROUND

Many smoking articles have been proposed through the years asimprovements upon, or alternatives to, smoking products based uponcombusting tobacco. Example alternatives have included devices wherein asolid or liquid fuel is combusted to transfer heat to tobacco or whereina chemical reaction is used to provide such heat source. Examplesinclude the smoking articles described in U.S. Pat. No. 9,078,473 toWorm et al., which is incorporated herein by reference.

The point of the improvements or alternatives to smoking articlestypically has been to provide the sensations associated with cigarette,cigar, or pipe smoking, without delivering considerable quantities ofincomplete combustion and pyrolysis products. To this end, there havebeen proposed numerous smoking products, flavor generators, andmedicinal inhalers which utilize electrical energy to vaporize or heat avolatile material, or attempt to provide the sensations of cigarette,cigar, or pipe smoking without burning tobacco to a significant degree.See, for example, the various alternative smoking articles, aerosoldelivery devices and heat generating sources set forth in the backgroundart described in U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat.App. Pub. No. 2013/0255702 to Griffith, Jr. et al., and U.S. Pat. App.Pub. No. 2014/0096781 to Sears et al., which are incorporated herein byreference. See also, for example, the various types of smoking articles,aerosol delivery devices and electrically powered heat generatingsources referenced by brand name and commercial source in U.S. Pat. App.Pub. No. 2015/0220232 to Bless et al., which is incorporated herein byreference. Additional types of smoking articles, aerosol deliverydevices and electrically powered heat generating sources referenced bybrand name and commercial source are listed in U.S. Pat. App. Pub. No.2015/0245659 to DePiano et al., which is also incorporated herein byreference. Other representative cigarettes or smoking articles that havebeen described and, in some instances, been made commercially availableinclude those described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S.Pat. Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S.Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,249,586 to Morganet al., U.S. Pat. No. 5,388,594 to Counts et al., U.S. Pat. No.5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al.,U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S.Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols,U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi,U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat. No. 7,896,006 toHamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. Pub. No.2009/0095311 to Hon, U.S. Pat. Pub. Nos. 2006/0196518, 2009/0126745, and2009/0188490 to Hon, U.S. Pat. Pub. No. 2009/0272379 to Thorens et al.,U.S. Pat. Pub. Nos. 2009/0260641 and 2009/0260642 to Monsees et al.,U.S. Pat. Pub. Nos. 2008/0149118 and 2010/0024834 to Oglesby et al.,U.S. Pat. Pub. No. 2010/0307518 to Wang, and PCT Pat. App. Pub. No. WO2010/091593 to Hon, which are incorporated herein by reference.

Representative products that resemble many of the attributes oftraditional types of cigarettes, cigars or pipes have been marketed asACCORD® by Philip Morris Incorporated; ALPHA™, JOYE 510™ and M4™ byInnoVapor LLC; CIRRUS™ and FLING™ by White Cloud Cigarettes; BLU™ byFontem Ventures B.V.; COHITA™, COLIBRI™, ELITE CLASSIC™, MAGNUM™,PHANTOM™ and SENSE™ by EPUFFER® International Inc.; DUOPRO™, STORM™ andVAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by Egar Australia;eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd; EONSMOKE® byEonsmoke LLC; FIN™ by FIN Branding Group, LLC; SMOKE® by Green SmokeInc. USA; GREENARETTE™ by Greenarette LLC; HALLIGAN™, HENDU™, JET™,MAXXQ™, PINK™ and PITBULL™ by SMOKE STIK®; HEATBAR™ by Philip MorrisInternational, Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7; LOGIC™ andTHE CUBAN™ by LOGIC Technology; LUCI® by Luciano Smokes Inc.; METRO® byNicotek, LLC; NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SS ChoiceLLC; PREMIUM ELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPP E-MYSTICK™by Ruyan America, Inc.; RED DRAGON™ by Red Dragon Products, LLC; RUYAN®by Ruyan Group (Holdings) Ltd.; SF® by Smoker Friendly International,LLC; GREEN SMART SMOKER® by The Smart Smoking Electronic CigaretteCompany Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC; VUSE® by R. J. Reynolds Vapor Company; MISTICMENTHOL product by Mistic Ecigs; the VYPE product by CN Creative Ltd;IQOS™ by Philip Morris International; GLO™ by British American Tobacco;MARK TEN products by Nu Mark LLC; and the JUUL product by Juul Labs,Inc. Yet other electrically powered aerosol delivery devices, and inparticular those devices that have been characterized as so-calledelectronic cigarettes, have been marketed under the tradenames COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP®; and SOUTH BEACHSMOKE™. However, it may be desirable to provide aerosol delivery deviceswith improved electronics such as may extend usability of the devices.

BRIEF SUMMARY

The present disclosure relates to aerosol delivery devices configured toproduce aerosol and which aerosol delivery devices, in someimplementations, may be referred to as electronic cigarettes orheat-not-burn cigarettes. The present disclosure includes, withoutlimitation, the following example implementations.

Some example implementations provide an aerosol delivery devicecomprising: a housing structured to retain an aerosol precursorcomposition; a heating element configured to convert electricity to heatand thereby vaporize components of the aerosol precursor composition; apower source including one or more batteries or battery cells coupled toand configured to power a load including the heating element; and chargecircuitry coupled to and configured to controllably charge the powersource, the charge circuitry including: an electrical connectorconfigured to connect the charge circuitry to a power supply from whichthe power source is chargeable; and a buck-boost charge controllercoupled to and between the power source and power supply, and configuredto regulate output voltage and output current from the power supply tothe power source, selectively in one of a plurality of modes based on acondition of the power supply.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the power source includes a plurality ofbatteries or battery cells.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the plurality of batteries or battery cells areconnected to form a plurality of paths for the output current from thepower supply to flow through such that the output current is a sum ofcurrents through each path of the plurality of paths.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the one or more batteries or battery cellsinclude one or more lithium-ion, lithium iron phosphate, supercapacitoror solid state batteries or battery cells.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the power supply includes one or morelithium-ion or solid state batteries, or lithium-ion or hybridlithium-ion capacitors, and the buck-boost charge controller beingconfigured to regulate the output voltage and output current from thepower supply includes being configured to regulate the output voltageand output current from the one or more lithium-ion or solid statebatteries, or lithium-ion or hybrid lithium-ion capacitors.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the charge circuitry further includes aprotection circuit coupled to and between the electrical connector andthe power source, and configured to protect the power source from anovercurrent condition in the power supply when the electrical connectoris coupled to the power supply.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the protection circuit includes a switchconfigured to interrupt the output current from the power supply to thepower source when the power supply is in the overcurrent condition.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the buck-boost charge controller beingconfigured to regulate the output voltage and output current includesbeing configured to limit the output current to a maximum current when aterminal voltage of the power source falls below a threshold voltagewhen the power source is charged from the power supply.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the aerosol precursor composition is a liquid,or a solid or semi-solid.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the aerosol delivery device further comprises anon-inverting unity gain operational amplifier coupled to the heatingelement and configured to output a constant power to the heatingelement. The operational amplifier acts a buffer to amplify the signalwhich may get attenuated. Usually a unity gain is designed but the gainmay be more than 1 depending on the attenuation of the signal.

In some example implementations of the aerosol delivery device of anypreceding example implementation, or any combination of any precedingexample implementations, the plurality of modes includes two or more ofa buck mode, a boost mode or a buck-boost mode.

Some example implementations provide a control body for an aerosoldelivery device, the control body comprising: a heating element orterminals configured to connect the heating element to the control body,the heating element being configured to convert electricity to heat andthereby vaporize components of an aerosol precursor composition; a powersource including one or more batteries or battery cells coupled to andconfigured to power a load including the heating element; and chargecircuitry coupled to and configured to controllably charge the powersource, the charge circuitry including: an electrical connectorconfigured to connect the charge circuitry to a power supply from whichthe power source is chargeable; and a buck-boost charge controllercoupled to and between the power source and power supply, and configuredto regulate output voltage and output current from the power supply tothe power source, selectively in one of a plurality of modes based on acondition of the power supply.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the power source includes a plurality of batteries orbattery cells. In some example implementations of the control body ofany preceding example implementation, or any combination of anypreceding example implementations, the plurality of batteries or batterycells are connected to form a plurality of paths for the output currentfrom the power supply to flow through such that the output current is asum of currents through each path of the plurality of paths.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the one or more batteries or battery cells include oneor more lithium-ion, lithium iron phosphate or solid state batteries orbattery cells.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the power supply includes one or more lithium-ion orsolid state batteries, or lithium-ion or hybrid lithium-ion capacitors,and the buck-boost charge controller being configured to regulate theoutput voltage and output current from the power supply includes beingconfigured to regulate the output voltage and output current from theone or more lithium-ion or solid state batteries, or lithium-ion orhybrid lithium-ion capacitors.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the charge circuitry further includes a protectioncircuit coupled to and between the electrical connector and the powersource, and configured to protect the power source from an overcurrentcondition in the power supply when the electrical connector is coupledto the power supply.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the protection circuit includes a switch configured tointerrupt the output current from the power supply to the power sourcewhen the power supply is in the overcurrent condition.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the buck-boost charge controller being configured toregulate the output voltage and output current includes being configuredto limit the output current to a maximum current when a terminal voltageof the power source falls below a threshold voltage when the powersource is charged from the power supply.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the aerosol precursor composition is a liquid, or asolid or semi-solid.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the control body further comprises a non-invertingunity gain operational amplifier coupled to the heating element andconfigured to output a constant power to the heating element.

In some example implementations of the control body of any precedingexample implementation, or any combination of any preceding exampleimplementations, the plurality of modes includes two or more of a buckmode, a boost mode or a buck-boost mode.

These and other features, aspects, and advantages of the presentdisclosure will be apparent from a reading of the following detaileddescription together with the accompanying drawings, which are brieflydescribed below. The present disclosure includes any combination of two,three, four or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedor otherwise recited in a specific example implementation describedherein. This disclosure is intended to be read holistically such thatany separable features or elements of the disclosure, in any of itsaspects and example implementations, should be viewed as combinable,unless the context of the disclosure clearly dictates otherwise.

It will therefore be appreciated that this Brief Summary is providedmerely for purposes of summarizing some example implementations so as toprovide a basic understanding of some aspects of the disclosure.Accordingly, it will be appreciated that the above described exampleimplementations are merely examples and should not be construed tonarrow the scope or spirit of the disclosure in any way. Other exampleimplementations, aspects and advantages will become apparent from thefollowing detailed description taken in conjunction with theaccompanying drawings which illustrate, by way of example, theprinciples of some described example implementations.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described aspects of the disclosure in the foregoing generalterms, reference will now be made to the accompanying figures, which arenot necessarily drawn to scale, and wherein:

FIG. 1 illustrates a perspective view of an aerosol delivery deviceincluding a cartridge and a control body that are coupled to oneanother, according to an example implementation of the presentdisclosure;

FIG. 2 is a partially cut-away view of the aerosol delivery device ofFIG. 1 in which the cartridge and control body are decoupled from oneanother, according to an example implementation;

FIGS. 3 and 4 illustrate a perspective view of an aerosol deliverydevice comprising a control body and an aerosol source member that arerespectively coupled to one another and decoupled from one another,according to another example implementation of the present disclosure;

FIGS. 5 and 6 illustrate respectively a front view of and a sectionalview through the aerosol delivery device of FIGS. 3 and 4, according toan example implementation; and

FIGS. 7A and 7B are circuit diagrams of an aerosol delivery deviceaccording to various example implementations of the present disclosure.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter withreference to example implementations thereof. These exampleimplementations are described so that this disclosure will be thoroughand complete, and will fully convey the scope of the disclosure to thoseskilled in the art. Indeed, the disclosure may be embodied in manydifferent forms and should not be construed as limited to theimplementations set forth herein; rather, these implementations areprovided so that this disclosure will satisfy applicable legalrequirements. As used in the specification and the appended claims, thesingular forms “a,” “an,” “the” and the like include plural referentsunless the context clearly dictates otherwise. Also, while reference maybe made herein quantitative measures, values, geometric relationships orthe like, unless otherwise stated, any one or more if not all of thesemay be absolute or approximate to account for acceptable variations thatmay occur, such as those due to engineering tolerances or the like.

As described hereinafter, example implementations of the presentdisclosure relate to aerosol delivery devices. Aerosol delivery devicesaccording to the present disclosure use electrical energy to heat amaterial (preferably without combusting the material to any significantdegree) to form an inhalable substance; and components of such systemshave the form of articles most preferably are sufficiently compact to beconsidered hand-held devices. That is, use of components of preferredaerosol delivery devices does not result in the production of smoke inthe sense that aerosol results principally from by-products ofcombustion or pyrolysis of tobacco, but rather, use of those preferredsystems results in the production of vapors resulting fromvolatilization or vaporization of certain components incorporatedtherein. In some example implementations, components of aerosol deliverydevices may be characterized as electronic cigarettes, and thoseelectronic cigarettes most preferably incorporate tobacco and/orcomponents derived from tobacco, and hence deliver tobacco derivedcomponents in aerosol form.

Aerosol generating components of certain preferred aerosol deliverydevices may provide many of the sensations (e.g., inhalation andexhalation rituals, types of tastes or flavors, organoleptic effects,physical feel, use rituals, visual cues such as those provided byvisible aerosol, and the like) of smoking a cigarette, cigar or pipethat is employed by lighting and burning tobacco (and hence inhalingtobacco smoke), without any substantial degree of combustion of anycomponent thereof. For example, the user of an aerosol delivery devicein accordance with some example implementations of the presentdisclosure can hold and use that component much like a smoker employs atraditional type of smoking article, draw on one end of that componentfor inhalation of aerosol produced by that component, take or draw puffsat selected intervals of time, and the like.

While the systems are generally described herein in terms ofimplementations associated with aerosol delivery devices such asso-called “e-cigarettes,” “tobacco heating products” and the like, itshould be understood that the mechanisms, components, features, andmethods may be embodied in many different forms and associated with avariety of articles. For example, the description provided herein may beemployed in conjunction with implementations of traditional smokingarticles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burncigarettes, and related packaging for any of the products disclosedherein. Accordingly, it should be understood that the description of themechanisms, components, features, and methods disclosed herein arediscussed in terms of implementations relating to aerosol deliverydevices by way of example only, and may be embodied and used in variousother products and methods.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer housing, which may bereferred to as a body or shell. The overall design of the housing canvary, and the format or configuration of the housing that can define theoverall size and shape of the aerosol delivery device can vary.Typically, an elongated body resembling the shape of a cigarette orcigar can be a formed from a single, unitary housing or the elongatedhousing can be formed of two or more separable bodies. For example, anaerosol delivery device can comprise an elongated housing that can besubstantially tubular in shape and, as such, resemble the shape of aconventional cigarette or cigar. In one example, all of the componentsof the aerosol delivery device are contained within one housing.Alternatively, an aerosol delivery device can comprise two or morehousings that are joined and are separable. For example, an aerosoldelivery device can possess at one end a control body comprising ahousing containing one or more reusable components (e.g., an accumulatorsuch as a rechargeable battery and/or rechargeable supercapacitor, andvarious electronics for controlling the operation of that article), andat the other end and removably and coupleable thereto, an outer body orshell containing a disposable portion (e.g., a disposableflavor-containing cartridge). More specific formats, configurations andarrangements of components within the single housing type of unit orwithin a multi-piece separable housing type of unit will be evident inlight of the further disclosure provided herein. Additionally, variousaerosol delivery device designs and component arrangements can beappreciated upon consideration of the commercially available electronicaerosol delivery devices. It will be appreciated that alternativenon-tubular housing form factors can also be used, including, forexample, device housings having a shape and size generally approximatinga pack of cigarettes and form factors such as used on the GLO™ byBritish American Tobacco and IQOS™ by Philip Morris International, Inc.

As will be discussed in more detail below, aerosol delivery devices ofthe present disclosure comprise some combination of a power source(i.e., an electrical power source), at least one control component(e.g., means for actuating, controlling, regulating and ceasing powerfor heat generation, such as by controlling electrical current flow fromthe power source to other components of the aerosol delivery device), aheating element (e.g., an electrical resistance heating element or othercomponent and/or an inductive coil or other associated components and/orone or more radiant heating elements), and an aerosol precursorcomposition (e.g., a solid tobacco material, a semi-solid tobaccomaterial or a liquid aerosol precursor composition) capable of yieldingan aerosol upon application of sufficient heat, and a mouth end regionor tip to allow drawing upon the aerosol delivery device for aerosolinhalation (e.g., a defined airflow path through the article such thataerosol generated can be withdrawn therefrom upon draw).

Alignment of the components within the aerosol delivery device of thepresent disclosure can vary. In specific implementations, the aerosolprecursor composition can be located near an end of the aerosol deliverydevice which may be configured to be positioned proximal to the mouth ofa user so as to maximize aerosol delivery to the user. Otherconfigurations, however, are not excluded. Generally, the heatingelement may be positioned sufficiently near the aerosol precursorcomposition so that heat from the heating element can volatilize theaerosol precursor (as well as one or more flavorants, medicaments, orthe like that may likewise be provided for delivery to a user) and forman aerosol for delivery to the user. When the heating element heats theaerosol precursor composition, an aerosol is formed, released, orgenerated in a physical form suitable for inhalation by a consumer. Itshould be noted that the foregoing terms are meant to be interchangeablesuch that reference to release, releasing, releases, or releasedincludes form or generate, forming or generating, forms or generates,and formed or generated. Specifically, an inhalable substance isreleased in the form of a vapor or aerosol or mixture thereof, whereinsuch terms are also interchangeably used herein except where otherwisespecified.

As noted above, the aerosol delivery device may incorporate a battery.Supercapacitor, solid state battery or other power source to providecurrent flow sufficient to provide various functionalities to theaerosol delivery device, such as powering of a heating element, poweringof control systems, powering of indicators, and the like. The powersource can take on various implementations. Preferably, the power sourceis able to deliver sufficient power to rapidly activate the heatingelement to provide for aerosol formation and power the aerosol deliverydevice through use for a desired duration of time. The power sourcepreferably is sized to fit conveniently within the aerosol deliverydevice so that the aerosol delivery device can be easily handled.Additionally, a preferred power source is of a sufficiently light weightto not detract from a desirable smoking experience.

More specific formats, configurations and arrangements of componentswithin the aerosol delivery device of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices. Further, the arrangementof the components within the aerosol delivery device can also beappreciated upon consideration of the commercially available electronicaerosol delivery devices.

As described hereinafter, the present disclosure relates to aerosoldelivery devices. Aerosol delivery devices may be configured to heat anaerosol precursor composition (sometimes referred to as an inhalablesubstance medium) to produce an aerosol (an inhalable substance). Theaerosol precursor composition may comprise one or more of a solidtobacco material, a semi-solid tobacco material, and a liquid aerosolprecursor composition. In some implementations, the aerosol deliverydevices may be configured to heat and produce an aerosol from a fluidaerosol precursor composition (e.g., a liquid aerosol precursorcomposition). Such aerosol delivery devices may include so-calledelectronic cigarettes.

Liquid aerosol precursor composition, also referred to as a vaporprecursor composition or “e-liquid,” may comprise a variety ofcomponents including, by way of example, a polyhydric alcohol (e.g.,glycerin, propylene glycol, or a mixture thereof), nicotine, tobacco,tobacco extract, and/or flavorants. Some liquid aerosol precursorcompositions that may be used in conjunction with variousimplementations may include one or more acids such as levulinic acid,succinic acid, lactic acid, pyruvic acid, benzoic acid, fumaric acid,combinations thereof, and the like. Inclusion of an acid(s) in liquidaerosol precursor compositions including nicotine may provide aprotonated liquid aerosol precursor composition, including nicotine insalt form. Representative types of liquid aerosol precursor componentsand formulations are set forth and characterized in U.S. Pat. No.7,726,320 to Robinson et al., U.S. Pat. No. 9,254,002 to Chong et al.,and U.S. Pat. App. Pub. Nos. 2013/0008457 to Zheng et al., 2015/0020823to Lipowicz et al., and 2015/0020830 to Koller, as well as PCT Pat. App.Pub. No. WO 2014/182736 to Bowen et al., and U.S. Pat. No. 8,881,737 toCollett et al., the disclosures of which are incorporated herein byreference. Other aerosol precursors that may be employed include theaerosol precursors that have been incorporated in any of a number of therepresentative products identified above. Also desirable are theso-called “smoke juices” for electronic cigarettes that have beenavailable from Johnson Creek Enterprises LLC. Still further exampleaerosol precursor compositions are sold under the brand names BLACKNOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THE VAPOR CHEF, VAPEWILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEY JONES MAINLINERESERVE, MITTEN VAPORS, DR. CRIMMY'S V-LIQUID, SMILEY E LIQUID, BEANTOWNVAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFE VAPOR, TELEOS, PINUPVAPORS, SPACE JAM, MT. BAKER VAPOR, and JIMMY THE JUICE MAN.Implementations of effervescent materials can be used with the aerosolprecursor, and are described, by way of example, in U.S. Pat. App. Pub.No. 2012/0055494 to Hunt et al., which is incorporated herein byreference. Further, the use of effervescent materials is described, forexample, in U.S. Pat. No. 4,639,368 to Niazi et al., U.S. Pat. No.5,178,878 to Wehling et al., U.S. Pat. No. 5,223,264 to Wehling et al.,U.S. Pat. No. 6,974,590 to Pather et al., U.S. Pat. No. 7,381,667 toBergquist et al., U.S. Pat. No. 8,424,541 to Crawford et al, U.S. Pat.No. 8,627,828 to Strickland et al., and U.S. Pat. No. 9,307,787 to Sunet al., as well as U.S. Pat. App. Pub. Nos. 2010/0018539 to Brinkley etal., and PCT Pat. App. Pub. No. WO 97/06786 to Johnson et al., all ofwhich are incorporated by reference herein.

Representative types of substrates, reservoirs or other components forsupporting the aerosol precursor are described in U.S. Pat. No.8,528,569 to Newton, U.S. Pat. App. Pub. No. 2014/0261487 to Chapman etal., U.S. Pat. App. Pub. No. 2015/0059780 to Davis et al., and U.S. Pat.App. Pub. No. 2015/0216232 to Bless et al., all of which areincorporated herein by reference. Additionally, various wickingmaterials, and the configuration and operation of those wickingmaterials within certain types of electronic cigarettes, are set forthin U.S. Pat. No. 8,910,640 to Sears et al., which is incorporated hereinby reference.

In other implementations, the aerosol delivery devices may compriseheat-not-burn devices, configured to heat a solid aerosol precursorcomposition (e.g., an extruded tobacco rod) or a semi-solid aerosolprecursor composition (e.g., a glycerin-loaded tobacco paste). Theaerosol precursor composition may comprise tobacco-containing beads,tobacco shreds, tobacco strips, reconstituted tobacco material, orcombinations thereof, and/or a mix of finely ground tobacco, tobaccoextract, spray dried tobacco extract, or other tobacco form mixed withoptional inorganic materials (such as calcium carbonate), optionalflavors, and aerosol forming materials to form a substantially solid ormoldable (e.g., extrudable) substrate. Representative types of solid andsemi-solid aerosol precursor compositions and formulations are disclosedin U.S. Pat. No. 8,424,538 to Thomas et al., U.S. Pat. No. 8,464,726 toSebastian et al., U.S. Pat. App. Pub. No. 2015/0083150 to Conner et al.,U.S. Pat. App. Pub. No. 2015/0157052 to Ademe et al., and U.S. Pat. App.Pub. No. 2017/0000188 to Nordskog et al., all of which are incorporatedby reference herein. Further representative types of solid andsemi-solid aerosol precursor compositions and arrangements include thosefound in the NEOSTIKS™ consumable aerosol source members for the GLO™product by British American Tobacco and in the HEETS™ consumable aerosolsource members for the IQOS™ product by Philip Morris International,Inc.

In various implementations, the inhalable substance specifically may bea tobacco component or a tobacco-derived material (i.e., a material thatis found naturally in tobacco that may be isolated directly from thetobacco or synthetically prepared). For example, the aerosol precursorcomposition may comprise tobacco extracts or fractions thereof combinedwith an inert substrate. The aerosol precursor composition may furthercomprise unburned tobacco or a composition containing unburned tobaccothat, when heated to a temperature below its combustion temperature,releases an inhalable substance. In some implementations, the aerosolprecursor composition may comprise tobacco condensates or fractionsthereof (i.e., condensed components of the smoke produced by thecombustion of tobacco, leaving flavors and, possibly, nicotine).

Tobacco materials useful in the present disclosure can vary and mayinclude, for example, flue-cured tobacco, burley tobacco, Orientaltobacco or Maryland tobacco, dark tobacco, dark-fired tobacco andRustica tobaccos, as well as other rare or specialty tobaccos, or blendsthereof. Tobacco materials also can include so-called “blended” formsand processed forms, such as processed tobacco stems (e.g., cut-rolledor cut-puffed stems), volume expanded tobacco (e.g., puffed tobacco,such as dry ice expanded tobacco (DIET), preferably in cut filler form),reconstituted tobaccos (e.g., reconstituted tobaccos manufactured usingpaper-making type or cast sheet type processes). Various representativetobacco types, processed types of tobaccos, and types of tobacco blendsare set forth in U.S. Pat. No. 4,836,224 to Lawson et al., U.S. Pat. No.4,924,888 to Perfetti et al., U.S. Pat. No. 5,056,537 to Brown et al.,U.S. Pat. No. 5,159,942 to Brinkley et al., U.S. Pat. No. 5,220,930 toGentry, U.S. Pat. No. 5,360,023 to Blakley et al., U.S. Pat. No.6,701,936 to Shafer et al., U.S. Pat. No. 7,011,096 to Li et al., andU.S. Pat. No. 7,017,585 to Li et al., U.S. Pat. No. 7,025,066 to Lawsonet al., U.S. Pat. App. Pub. No. 2004/0255965 to Perfetti et al., PCTPat. App. Pub. No. WO 02/37990 to Bereman, and Bombick et al., Fund.Appl. Toxicol., 39, p. 11-17 (1997), which are incorporated herein byreference. Further example tobacco compositions that may be useful in asmoking device, including according to the present disclosure, aredisclosed in U.S. Pat. No. 7,726,320 to Robinson et al., which isincorporated herein by reference.

Still further, the aerosol precursor composition may comprise an inertsubstrate having the inhalable substance, or a precursor thereof,integrated therein or otherwise deposited thereon. For example, a liquidcomprising the inhalable substance may be coated on or absorbed oradsorbed into the inert substrate such that, upon application of heat,the inhalable substance is released in a form that can be withdrawn fromthe inventive article through application of positive or negativepressure. In some aspects, the aerosol precursor composition maycomprise a blend of flavorful and aromatic tobaccos in cut filler form.In another aspect, the aerosol precursor composition may comprise areconstituted tobacco material, such as described in U.S. Pat. No.4,807,809 to Pryor et al., U.S. Pat. No. 4,889,143 to Pryor et al. andU.S. Pat. No. 5,025,814 to Raker, the disclosures of which areincorporated herein by reference. For further information regardingsuitable aerosol precursor composition, see U.S. patent application Ser.No. 15/916,834 to Sur et al., filed Mar. 9, 2018, which is incorporatedherein by reference.

Regardless of the type of aerosol precursor composition heated, aerosoldelivery devices may include a heating element configured to heat theaerosol precursor composition. In some implementations, the heatingelement is an induction heater. Such heaters often comprise an inductiontransmitter and an induction receiver. The induction transmitter mayinclude a coil configured to create an oscillating magnetic field (e.g.,a magnetic field that varies periodically with time) when alternatingcurrent is directed through it. The induction receiver may be at leastpartially located or received within the induction transmitter and mayinclude a conductive material (ferromagnetic material or an Aluminumcoated material). By directing alternating current through the inductiontransmitter, eddy currents may be generated in the induction receivervia induction. The eddy currents flowing through the resistance of thematerial defining the induction receiver may heat it by Joule heating(i.e., through the Joule effect). The induction receiver, which maydefine an atomizer, may be wirelessly heated to form an aerosol from anaerosol precursor composition positioned in proximity to the inductionreceiver. Various implementations of an aerosol delivery device with aninduction heater are described in U.S. Pat. App. Pub. No. 2017/0127722to Davis et al., U.S. Pat. App. Pub. No. 2017/0202266 to Sur et al.,U.S. patent application Ser. No. 15/352,153 to Sur et al., filed Nov.15, 2016, U.S. patent application Ser. No. 15/799,365 to Sebastian etal., filed Oct. 31, 2017, and U.S. patent application Ser. No.15/836,086 to Sur, all of which are incorporated by reference herein.

In other implementations including those described more particularlyherein, the heating element is a conductive heater such as in the caseof electrical resistance heater. These heaters may be configured toproduce heat when an electrical current is directed through it. Invarious implementations, a conductive heater may be provided in avariety forms, such as in the form of a foil, a foam, discs, spirals,fibers, wires, films, yarns, strips, ribbons or cylinders. Such heatersoften include a metal material and are configured to produce heat as aresult of the electrical resistance associated with passing anelectrical current through it. Such resistive heaters may be positionedin proximity to and heat an aerosol precursor composition to produce anaerosol. A variety of conductive substrates that may be usable with thepresent disclosure are described in the above-cited U.S. Pat. App. Pub.No. 2013/0255702 to Griffith et al.

In some implementations aerosol delivery devices may include a controlbody and a cartridge in the case of so-called electronic cigarettes, ora control body and an aerosol source member in the case of heat-not-burndevices. In the case of either electronic cigarettes or heat-not-burndevices, the control body may be reusable, whereas the cartridge/aerosolsource member may be configured for a limited number of uses and/orconfigured to be disposable. The cartridge/aerosol source member mayinclude the aerosol precursor composition. In order to heat the aerosolprecursor composition, the heating element may be positioned in contactwith or proximate the aerosol precursor composition, such as across thecontrol body and cartridge, or in the control body in which the aerosolsource member may be positioned. The control body may include a powersource, which may be rechargeable or replaceable, and thereby thecontrol body may be reused with multiple cartridges/aerosol sourcemembers.

The control body may also include means to activate the aerosol deliverydevice such as a pushbutton, touch-sensitive surface or the like formanual control of the device. Additionally or alternatively, the controlbody may include a flow sensor to detect when a user draws on thecartridge/aerosol source member to thereby activate the aerosol deliverydevice.

In various implementations, the aerosol delivery device according to thepresent disclosure may have a variety of overall shapes, including, butnot limited to an overall shape that may be defined as beingsubstantially rod-like or substantially tubular shaped or substantiallycylindrically shaped. In the implementations shown in and described withreference to the accompanying figures, the aerosol delivery device has asubstantially round cross-section; however, other cross-sectional shapes(e.g., oval, square, rectangle, triangle, etc.) also are encompassed bythe present disclosure. Such language that is descriptive of thephysical shape of the article may also be applied to the individualcomponents thereof, including the control body and the cartridge/aerosolsource member. In other implementations, the control body may takeanother handheld shape, such as a small box shape.

In more specific implementations, one or both of the control body andthe cartridge/aerosol source member may be referred to as beingdisposable or as being reusable. For example, the control body may havea power source such as a replaceable battery or a rechargeable battery,solid-state battery, thin-film solid-state battery, rechargeablesupercapacitor or the like. One example of a power source is a TKI-1550rechargeable lithium-ion battery produced by Tadiran Batteries GmbH ofGermany. In another implementation, a useful power source may be aN50-AAA CADNICA nickel-cadmium cell produced by Sanyo Electric Company,Ltd., of Japan. In other implementations, a plurality of such batteries,for example providing 1.2-volts each, may be connected in series.

In some examples, then, the power source may be connected to and therebycombined with any type of recharging technology. Examples of suitablechargers include chargers that simply supply constant or pulsed directcurrent (DC) power to the power source, fast chargers that add controlcircuitry, three-stage chargers, induction-powered chargers, smartchargers, motion-powered chargers, pulsed chargers, solar chargers,USB-based chargers and the like. In some examples, the charger includesa power adapter and any suitable charge circuitry. In other examples,the charger includes the power adapter and the control body is equippedwith charge circuitry. In these other examples, the charger may at timesbe simply referred to as a power adapter.

The control body may include any of a number of different terminals,electrical connectors or the like to connect to a suitable charger, andin some examples, to connect to other peripherals for communication.More specific suitable examples include direct current (DC) connectorssuch as cylindrical connectors, cigarette lighter connectors and USBconnectors including those specified by USB 1.x (e.g., Type A, Type B),USB 2.0 and its updates and additions (e.g., Mini A, Mini B, Mini AB,Micro A, Micro B, Micro AB) and USB 3.x (e.g., Type A, Type B, Micro B,Micro AB, Type C), proprietary connectors such as Apple's Lightningconnector, and the like. The control body may directly connect with thecharger or other peripheral, or the two may connect via an appropriatecable that also has suitable connectors. In examples in which the twoare connected by cable, the control body and charger or other peripheralmay have the same or different type of connector with the cable havingthe one type of connector or both types of connectors.

In examples involving induction-powered charging, the aerosol deliverydevice may be equipped with inductive wireless charging technology andinclude an induction receiver to connect with a wireless charger,charging pad or the like that includes an induction transmitter and usesinductive wireless charging (including for example, wireless chargingaccording to the Qi wireless charging standard from the Wireless PowerConsortium (WPC)). Or the power source may be recharged from a wirelessradio frequency (RF) based charger. An example of an inductive wirelesscharging system is described in U.S. Pat. App. Pub. No. 2017/0112196 toSur et al., which is incorporated herein by reference in its entirety.Further, in some implementations in the case of an electronic cigarette,the cartridge may comprise a single-use cartridge, as disclosed in U.S.Pat. No. 8,910,639 to Chang et al., which is incorporated herein byreference.

One or more connections may be employed to connect the power source to arecharging technology, and some may involve a charging case, cradle,dock, sleeve or the like. More specifically, for example, the controlbody may be configured to engage a cradle that includes a USB connectorto connect to a power supply. Or in another example, the control bodymay be configured to fit within and engage a sleeve that includes a USBconnector to connect to a power supply. In these and similar examples,the USB connector may connect directly to the power source, or the USBconnector may connect to the power source via a suitable power adapter.

Examples of power sources are described in U.S. Pat. No. 9,484,155 toPeckerar et al., and U.S. Pat. App. Pub. No. 2017/0112191 to Sur et al.,filed Oct. 21, 2015, the disclosures of which are incorporated herein byreference. With respect to the flow sensor, representative currentregulating components and other current controlling components includingvarious microcontrollers, sensors, and switches for aerosol deliverydevices are described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S.Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al.,U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 toFleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., U.S. Pat.No. 8,205,622 to Pan, U.S. Pat. No. 8,881,737 to Collet et al., U.S.Pat. No. 9,423,152 to Ampolini et al., U.S. Pat. No. 9,439,454 toFernando et al., and U.S. Pat. App. Pub. No. 2015/0257445 to Henry etal., all of which are incorporated herein by reference.

An input element may be included with the aerosol delivery device (andmay replace or supplement a flow sensor). The input may be included toallow a user to control functions of the device and/or for output ofinformation to a user. Any component or combination of components may beutilized as an input for controlling the function of the device. Forexample, one or more pushbuttons may be used as described in U.S. Pub.No. 2015/0245658 to Worm et al., which is incorporated herein byreference. Likewise, a touchscreen may be used as described in U.S.patent application Ser. No. 14/643,626, filed Mar. 10, 2015, to Sears etal., which is incorporated herein by reference. As a further example,components adapted for gesture recognition based on specified movementsof the aerosol delivery device may be used as an input. See U.S. Pub.2016/0158782 to Henry et al., which is incorporated herein by reference.As still a further example, a capacitive sensor may be implemented onthe aerosol delivery device to enable a user to provide input, such asby touching a surface of the device on which the capacitive sensor isimplemented. In another example, a sensor capable of detecting a motionassociated with the device (e.g., accelerometer, gyroscope,photoelectric proximity sensor, etc.) may be implemented on the aerosoldelivery device to enable a user to provide input. Examples of suitablesensors are described in U.S. Pat. App. Pub. No. 2018/0132528 to Sur etal., and U.S. Pat. App. Pub. No. 2016/0158782 to Henry et al., which areincorporated herein by reference.

As indicated above, the aerosol delivery device may include at least onecontrol component. A suitable control component may include a number ofelectronic components, and in some examples may be formed of a printedcircuit board (PCB). In some examples, the electronic components includeprocessing circuitry configured to perform data processing, applicationexecution, or other processing, control or management services accordingto one or more example implementations. The processing circuitry mayinclude a processor embodied in a variety of forms such as at least oneprocessor core, microprocessor, coprocessor, controller, microcontrolleror various other computing or processing devices including one or moreintegrated circuits such as, for example, an ASIC (application specificintegrated circuit), an FPGA (field programmable gate array), somecombination thereof, or the like. In some examples, the processingcircuitry may include memory coupled to or integrated with theprocessor, and which may store data, computer program instructionsexecutable by the processor, some combination thereof, or the like.

In some examples, the control component may include one or moreinput/output peripherals, which may be coupled to or integrated with theprocessing circuitry. More particularly, the control component mayinclude a communication interface to enable wireless communication withone or more networks, computing devices or other appropriately-enableddevices. Examples of suitable communication interfaces are disclosed inU.S. Pat. App. Pub. No. 2016/0261020 to Marion et al., the content ofwhich is incorporated herein by reference. Another example of a suitablecommunication interface is the CC3200 single chip wirelessmicrocontroller unit (MCU) from Texas Instruments. And examples ofsuitable manners according to which the aerosol delivery device may beconfigured to wirelessly communicate are disclosed in U.S. Pat. App.Pub. No. 2016/0007651 to Ampolini et al., and U.S. Pat. App. Pub. No.2016/0219933 to Henry, Jr. et al., each of which is incorporated hereinby reference.

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. One example of a suitable component is anindicator such as light-emitting diodes (LEDs), quantum dot-based LEDsor the like, which may be illuminated with use of the aerosol deliverydevice. Examples of suitable LED components, and the configurations anduses thereof, are described in U.S. Pat. No. 5,154,192 to Sprinkel etal., U.S. Pat. No. 8,499,766 to Newton, U.S. Pat. No. 8,539,959 toScatterday, and U.S. Pat. No. 9,451,791 to Sears et al., all of whichare incorporated herein by reference.

Other indices of operation are also encompassed by the presentdisclosure. For example, visual indicators of operation also includechanges in light color or intensity to show progression of the smokingexperience. Tactile (haptic) indicators of operation and sound (audio)indicators of operation similarly are encompassed by the disclosure.Moreover, combinations of such indicators of operation also are suitableto be used in a single smoking article. According to another aspect, theaerosol delivery device may include one or more indicators or indicia,such as, for example, a display configured to provide informationcorresponding to the operation of the smoking article such as, forexample, the amount of power remaining in the power source, progressionof the smoking experience, indication corresponding to activating a heatsource, and/or the like.

Yet other components are also contemplated. For example, U.S. Pat. No.5,154,192 to Sprinkel et al. discloses indicators for smoking articles;U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses piezoelectric sensorsthat can be associated with the mouth-end of a device to detect user lipactivity associated with taking a draw and then trigger heating of aheating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses apuff sensor for controlling energy flow into a heating load array inresponse to pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148to Harris et al. discloses receptacles in a smoking device that includean identifier that detects a non-uniformity in infrared transmissivityof an inserted component and a controller that executes a detectionroutine as the component is inserted into the receptacle; U.S. Pat. No.6,040,560 to Fleischhauer et al. describes a defined executable powercycle with multiple differential phases; U.S. Pat. No. 5,934,289 toWatkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. No. 8,689,804 to Fernando et al. discloses identification systemsfor smoking devices; and PCT Pat. App. Pub. No. WO 2010/003480 by Flickdiscloses a fluid flow sensing system indicative of a puffin an aerosolgenerating system; all of the foregoing disclosures being incorporatedherein by reference.

Further examples of components related to electronic aerosol deliveryarticles and disclosing materials or components that may be used in thepresent article include U.S. Pat. No. 4,735,217 to Gerth et al., U.S.Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higginset al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 toFelter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No.7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No.7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. Nos.8,156,944 and 8,375,957 to Hon, U.S. Pat. No. 8,794,231 to Thorens etal., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254and 8,925,555 to Monsees et al., U.S. Pat. No. 9,220,302 to DePiano etal., U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490 to Hon, U.S.Pat. App. Pub. No. 2010/0024834 to Oglesby et al., U.S. Pat. App. Pub.No. 2010/0307518 to Wang, PCT Pat. App. Pub. No. WO 2010/091593 to Hon,and PCT Pat. App. Pub. No. WO 2013/089551 to Foo, each of which isincorporated herein by reference. Further, U.S. Pat. App. Pub. No.2017/0099877 to Worm et al., discloses capsules that may be included inaerosol delivery devices and fob-shape configurations for aerosoldelivery devices, and is incorporated herein by reference. A variety ofthe materials disclosed by the foregoing documents may be incorporatedinto the present devices in various implementations, and all of theforegoing disclosures are incorporated herein by reference.

Yet other features, controls or components that can be incorporated intoaerosol delivery devices of the present disclosure are described in U.S.Pat. No. 5,967,148 to Harris et al., U.S. Pat. No. 5,934,289 to Watkinset al., U.S. Pat. No. 5,954,979 to Counts et al., U.S. Pat. No.6,040,560 to Fleischhauer et al., U.S. Pat. No. 8,365,742 to Hon, U.S.Pat. No. 8,402,976 to Fernando et al., U.S. Pat. App. Pub. No.2005/0016550 to Katase, U.S. Pat. No. 8,689,804 to Fernando et al., U.S.Pat. App. Pub. No. 2013/0192623 to Tucker et al., U.S. Pat. No.9,427,022 to Leven et al., U.S. Pat. App. Pub. No. 2013/0180553 to Kimet al., U.S. Pat. App. Pub. No. 2014/0000638 to Sebastian et al., U.S.Pat. App. Pub. No. 2014/0261495 to Novak et al., and U.S. Pat. No.9,220,302 to DePiano et al., all of which are incorporated herein byreference.

FIGS. 1 and 2 illustrate implementations of an aerosol delivery deviceincluding a control body and a cartridge in the case of an electroniccigarette. More specifically, FIGS. 1 and 2 illustrate an aerosoldelivery device 100 according to an example implementation of thepresent disclosure. As indicated, the aerosol delivery device mayinclude a control body 102 and a cartridge 104. The control body and thecartridge can be permanently or detachably aligned in a functioningrelationship. In this regard, FIG. 1 illustrates a perspective view ofthe aerosol delivery device in a coupled configuration, whereas FIG. 2illustrates a partially cut-away side view of the aerosol deliverydevice in a decoupled configuration. The aerosol delivery device may,for example, be substantially rod-like, substantially tubular shaped, orsubstantially cylindrically shaped in some implementations when thecontrol body and the cartridge are in an assembled configuration.

The control body 102 and the cartridge 104 can be configured to engageone another by a variety of connections, such as a press fit (orinterference fit) connection, a threaded connection, a magneticconnection, or the like. As such, the control body may include a firstengaging element (e.g., a coupler) that is adapted to engage a secondengaging element (e.g., a connector) on the cartridge. The firstengaging element and the second engaging element may be reversible. Asan example, either of the first engaging element or the second engagingelement may be a male thread, and the other may be a female thread. As afurther example, either the first engaging element or the secondengaging element may be a magnet, and the other may be a metal or amatching magnet. In particular implementations, engaging elements may bedefined directly by existing components of the control body and thecartridge. For example, the housing of the control body may define acavity at an end thereof that is configured to receive at least aportion of the cartridge (e.g., a storage tank or other shell-formingelement of the cartridge). In particular, a storage tank of thecartridge may be at least partially received within the cavity of thecontrol body while a mouthpiece of the cartridge remains exposed outsideof the cavity of the control body. The cartridge may be retained withinthe cavity formed by the control body housing, such as by aninterference fit (e.g., through use of detents and/or other featurescreating an interference engagement between an outer surface of thecartridge and an interior surface of a wall forming the control bodycavity), by a magnetic engagement (e.g., though use of magnets and/ormagnetic metals positioned within the cavity of the control body andpositioned on the cartridge), or by other suitable techniques.

As seen in the cut-away view illustrated in FIG. 2, the control body 102and cartridge 104 each include a number of respective components. Thecomponents illustrated in FIG. 2 are representative of the componentsthat may be present in a control body and cartridge and are not intendedto limit the scope of components that are encompassed by the presentdisclosure. As shown, for example, the control body can be formed of ahousing 206 (sometimes referred to as a control body shell) that caninclude a control component 208 (e.g., processing circuitry, etc.), aflow sensor 210, a power source 212 (e.g., battery, supercapacitor), andan indicator 214 (e.g., LED, quantum dot-based LED), and such componentscan be variably aligned. The power source may be rechargeable, and thecontrol body may include charging circuitry 216 coupled to andconfigured to controllably charge the power source.

The cartridge 104 can be formed of a housing 218 (sometimes referred toas the cartridge shell) enclosing a reservoir 220 configured to retainthe aerosol precursor composition, and including a heating element 222(sometimes referred to as a heater). In various configurations, thisstructure may be referred to as a tank; and accordingly, the terms“cartridge,” “tank” and the like may be used interchangeably to refer toa shell or other housing enclosing a reservoir for aerosol precursorcomposition, and including a heating element.

As shown, in some examples, the reservoir 220 may be in fluidcommunication with a liquid transport element 224 adapted to wick orotherwise transport an aerosol precursor composition stored in thereservoir housing to the heating element 222. In some examples, a valvemay be positioned between the reservoir and heating element, andconfigured to control an amount of aerosol precursor composition passedor delivered from the reservoir to the heating element.

Various examples of materials configured to produce heat when electricalcurrent is applied therethrough may be employed to form the heatingelement 222. The heating element in these examples may be a resistiveheating element such as a wire coil, micro heater or the like. Examplematerials from which the heating element may be formed include Kanthal(FeCrAl), nichrome, nickel, stainless steel, indium tin oxide, tungsten,molybdenum disilicide (MoSi₂), molybdenum silicide (MoSi), molybdenumdisilicide doped with aluminum (Mo(Si,Al)₂), titanium, platinum, silver,palladium, alloys of silver and palladium, graphite and graphite-basedmaterials (e.g., carbon-based foams and yarns), conductive inks, borondoped silica, and ceramics (e.g., positive or negative temperaturecoefficient ceramics). The heating element may be resistive heatingelement or a heating element configured to generate heat throughinduction. The heating element may be coated by heat conductive ceramicssuch as aluminum nitride, silicon carbide, beryllium oxide, alumina,silicon nitride, or their composites. Example implementations of heatingelements useful in aerosol delivery devices according to the presentdisclosure are further described below, and can be incorporated intodevices such as those described herein.

An opening 226 may be present in the housing 218 (e.g., at the mouthend) to allow for egress of formed aerosol from the cartridge 104.

The cartridge 104 also may include one or more electronic components228, which may include an integrated circuit, a memory component (e.g.,EEPROM, flash memory), a sensor, or the like. The electronic componentsmay be adapted to communicate with the control component 208 and/or withan external device by wired or wireless means. The electronic componentsmay be positioned anywhere within the cartridge or a base 230 thereof.

Although the control component 208 and the flow sensor 210 areillustrated separately, it is understood that various electroniccomponents including the control component and the flow sensor may becombined on a PCB that supports and electrically connects the electroniccomponents. Further, the PCB may be positioned horizontally relative theillustration of FIG. 1 in that the PCB can be lengthwise parallel to thecentral axis of the control body. In some examples, the air flow sensormay comprise its own PCB or other base element to which it can beattached. In some examples, a flexible PCB may be utilized. A flexiblePCB may be configured into a variety of shapes, include substantiallytubular shapes. In some examples, a flexible PCB may be combined with,layered onto, or form part or all of a heater substrate.

The control body 102 and the cartridge 104 may include componentsadapted to facilitate a fluid engagement therebetween. As illustrated inFIG. 2, the control body can include a coupler 232 having a cavity 234therein. The base 230 of the cartridge can be adapted to engage thecoupler and can include a projection 236 adapted to fit within thecavity. Such engagement can facilitate a stable connection between thecontrol body and the cartridge as well as establish an electricalconnection between the power source 212 and control component 208 in thecontrol body and the heating element 222 in the cartridge. Further, thehousing 206 can include an air intake 238, which may be a notch in thehousing where it connects to the coupler that allows for passage ofambient air around the coupler and into the housing where it then passesthrough the cavity 234 of the coupler and into the cartridge through theprojection 236.

A coupler and a base useful according to the present disclosure aredescribed in U.S. Pat. App. Pub. No. 2014/0261495 to Novak et al., whichis incorporated herein by reference. For example, the coupler 232 asseen in FIG. 2 may define an outer periphery 240 configured to mate withan inner periphery 242 of the base 230. In one example the innerperiphery of the base may define a radius that is substantially equalto, or slightly greater than, a radius of the outer periphery of thecoupler. Further, the coupler may define one or more protrusions 244 atthe outer periphery configured to engage one or more recesses 246defined at the inner periphery of the base. However, various otherexamples of structures, shapes and components may be employed to couplethe base to the coupler. In some examples the connection between thebase of the cartridge 104 and the coupler of the control body 102 may besubstantially permanent, whereas in other examples the connectiontherebetween may be releasable such that, for example, the control bodymay be reused with one or more additional cartridges that may bedisposable and/or refillable.

The reservoir 220 illustrated in FIG. 2 can be a container or can be afibrous reservoir, as presently described. For example, the reservoircan comprise one or more layers of nonwoven fibers substantially formedinto the shape of a tube encircling the interior of the housing 218, inthis example. An aerosol precursor composition can be retained in thereservoir. Liquid components, for example, can be sorptively retained bythe reservoir. The reservoir can be in fluid connection with the liquidtransport element 224. The liquid transport element can transport theaerosol precursor composition stored in the reservoir via capillaryaction to the heating element 222 that is in the form of a metal wirecoil in this example. As such, the heating element is in a heatingarrangement with the liquid transport element.

In some examples, a microfluidic chip may be embedded in the reservoir220, and the amount and/or mass of aerosol precursor compositiondelivered from the reservoir may be controlled by a micro pump, such asone based on microelectromechanical systems (MEMS) technology. Otherexample implementations of reservoirs and transport elements useful inaerosol delivery devices according to the present disclosure are furtherdescribed herein, and such reservoirs and/or transport elements can beincorporated into devices such as those described herein. In particular,specific combinations of heating members and transport elements asfurther described herein may be incorporated into devices such as thosedescribed herein.

In use, when a user draws on the aerosol delivery device 100, airflow isdetected by the flow sensor 210, and the heating element 222 isactivated to vaporize components of the aerosol precursor composition.Drawing upon the mouth end of the aerosol delivery device causes ambientair to enter the air intake 238 and pass through the cavity 234 in thecoupler 232 and the central opening in the projection 236 of the base230. In the cartridge 104, the drawn air combines with the formed vaporto form an aerosol. The aerosol is whisked, aspirated or otherwise drawnaway from the heating element and out the opening 226 in the mouth endof the aerosol delivery device.

For further detail regarding implementations of an aerosol deliverydevice including a control body and a cartridge in the case of anelectronic cigarette, see the above-cited U.S. patent application Ser.No. 15/836,086 to Sur, and U.S. patent application Ser. No. 15/916,834to Sur et al., as well as U.S. patent application Ser. No. 15/916,696 toSur, filed Mar. 9, 2018, which is also incorporated herein by reference.

FIGS. 3-6 illustrate implementations of an aerosol delivery deviceincluding a control body and an aerosol source member in the case of aheat-not-burn device. More specifically, FIG. 3 illustrates an aerosoldelivery device 300 according to an example implementation of thepresent disclosure. The aerosol delivery device may include a controlbody 302 and an aerosol source member 304. In various implementations,the aerosol source member and the control body can be permanently ordetachably aligned in a functioning relationship. In this regard, FIG. 3illustrates the aerosol delivery device in a coupled configuration,whereas FIG. 4 illustrates the aerosol delivery device in a decoupledconfiguration. Various mechanisms may connect the aerosol source memberto the control body to result in a threaded engagement, a press-fitengagement, an interference fit, a sliding fit, a magnetic engagement,or the like.

As shown in FIG. 4, in various implementations of the presentdisclosure, the aerosol source member 304 may comprise a heated end 406,which is configured to be inserted into the control body 302, and amouth end 408, upon which a user draws to create the aerosol. In variousimplementations, at least a portion of the heated end may include anaerosol precursor composition 410.

In various implementations, the aerosol source member 304, or a portionthereof, may be wrapped in an exterior overwrap material 412, which maybe formed of any material useful for providing additional structureand/or support for the aerosol source member. In variousimplementations, the exterior overwrap material may comprise a materialthat resists transfer of heat, which may include a paper or otherfibrous material, such as a cellulose material. The exterior overwrapmaterial may also include at least one filler material imbedded ordispersed within the fibrous material. In various implementations, thefiller material may have the form of water insoluble particles.Additionally, the filler material may incorporate inorganic components.In various implementations, the exterior overwrap may be formed ofmultiple layers, such as an underlying, bulk layer and an overlyinglayer, such as a typical wrapping paper in a cigarette. Such materialsmay include, for example, lightweight “rag fibers” such as flax, hemp,sisal, rice straw, and/or esparto. The exterior overwrap may alsoinclude a material typically used in a filter element of a conventionalcigarette, such as cellulose acetate. Further, an excess length of theoverwrap at the mouth end 408 of the aerosol source member may functionto simply separate the aerosol precursor composition 410 from the mouthof a consumer or to provide space for positioning of a filter material,as described below, or to affect draw on the article or to affect flowcharacteristics of the vapor or aerosol leaving the device during draw.Further discussion relating to the configurations for overwrap materialsthat may be used with the present disclosure may be found in theabove-cited U.S. Pat. No. 9,078,473 to Worm et al.

In various implementations other components may exist between theaerosol precursor composition 410 and the mouth end 408 of the aerosolsource member 304, wherein the mouth end may include a filter 414, whichmay, for example, be made of a cellulose acetate or polypropylenematerial. The filter may additionally or alternatively contain strandsof tobacco containing material, such as described in U.S. Pat. No.5,025,814 to Raker et al., which is incorporated herein by reference inits entirety. In various implementations, the filter may increase thestructural integrity of the mouth end of the aerosol source member,and/or provide filtering capacity, if desired, and/or provide resistanceto draw. In some implementations one or any combination of the followingmay be positioned between the aerosol precursor composition and themouth end: an air gap; phase change materials for cooling air; flavorreleasing media; ion exchange fibers capable of selective chemicaladsorption; aerogel particles as filter medium; and other suitablematerials.

Various implementations of the present disclosure employ one or moreconductive heating elements to heat the aerosol precursor composition410 of the aerosol source member 304. In various implementations, theheating element may be provided in a variety forms, such as in the formof a foil, a foam, a mesh, a hollow ball, a half ball, discs, spirals,fibers, wires, films, yarns, strips, ribbons, or cylinders. Such heatingelements often comprise a metal material and are configured to produceheat as a result of the electrical resistance associated with passing anelectrical current therethrough. Such resistive heating elements may bepositioned in direct contact with, or in proximity to, the aerosolsource member and particularly, the aerosol precursor composition of theaerosol source member 304. The heating element may be located in thecontrol body and/or the aerosol source member. In variousimplementations, the aerosol precursor composition may includecomponents (i.e., heat conducting constituents) that are imbedded in, orotherwise part of, the substrate portion that may serve as, orfacilitate the function of, the heating assembly. Some examples ofvarious heating members and elements are described in U.S. Pat. No.9,078,473 to Worm et al.

Some non-limiting examples of various heating element configurationsinclude configurations in which a heating element is placed in proximitywith the aerosol source member 304. For instance, in some examples, atleast a portion of a heating element may surround at least a portion ofan aerosol source member. In other examples, one or more heatingelements may be positioned adjacent an exterior of an aerosol sourcemember when inserted in the control body 302. In other examples, atleast a portion of a heating element may penetrate at least a portion ofan aerosol source member (such as, for example, one or more prongsand/or spikes that penetrate an aerosol source member), when the aerosolsource member is inserted into the control body. In some instances, theaerosol precursor composition may include a structure in contact with,or a plurality of beads or particles imbedded in, or otherwise part of,the aerosol precursor composition that may serve as, or facilitate thefunction of the heating element.

FIG. 5 illustrates a front view of an aerosol delivery device 300according to an example implementation of the present disclosure, andFIG. 6 illustrates a sectional view through the aerosol delivery deviceof FIG. 5. In particular, the control body 302 of the depictedimplementation may comprise a housing 516 that includes an opening 518defined in an engaging end thereof, a flow sensor 520 (e.g., a puffsensor or pressure switch), a control component 522 (e.g., processingcircuitry, etc.), a power source 524 (e.g., battery, supercapacitor),and an end cap that includes an indicator 526 (e.g., a LED). The powersource may be rechargeable, and the control body may include chargingcircuitry 528 coupled to and configured to controllably charge the powersource.

In one implementation, the indicator 526 may comprise one or more LEDs,quantum dot-based LEDs or the like. The indicator can be incommunication with the control component 522 and be illuminated, forexample, when a user draws on the aerosol source member 304, whencoupled to the control body 302, as detected by the flow sensor 520.

The control body 302 of the depicted implementation includes one or moreheating assemblies 530 (individually or collectively referred to aheating assembly) configured to heat the aerosol precursor composition410 of the aerosol source member 304. Although the heating assembly ofvarious implementations of the present disclosure may take a variety offorms, in the particular implementation depicted in FIGS. 5 and 6, theheating assembly comprises an outer cylinder 532 and a heating element534, which in this implementation comprises a plurality of heater prongsthat extend from a receiving base 536 (in various configurations, theheating assembly or more specifically the heater prongs may be referredto as a heater). In the depicted implementation, the outer cylindercomprises a double-walled vacuum tube constructed of stainless steel soas to maintain heat generated by the heater prongs within the outercylinder, and more particularly, maintain heat generated by heaterprongs within the aerosol precursor composition. In variousimplementations, the heater prongs may be constructed of one or moreconductive materials, including, but not limited to, copper, aluminum,platinum, gold, silver, iron, steel, brass, bronze, graphite, or anycombination thereof.

As illustrated, the heating assembly 530 may extend proximate anengagement end of the housing 516, and may be configured tosubstantially surround a portion of the heated end 406 of the aerosolsource member 304 that includes the aerosol precursor composition 410.In such a manner, the heating assembly may define a generally tubularconfiguration. As illustrated in FIGS. 5 and 6, the heating element 534(e.g., plurality of heater prongs) is surrounded by the outer cylinder532 to create a receiving chamber 538. In such a manner, in variousimplementations the outer cylinder may comprise a nonconductiveinsulating material and/or construction including, but not limited to,an insulating polymer (e.g., plastic or cellulose), glass, rubber,ceramic, porcelain, a double-walled vacuum structure, or anycombinations thereof.

In some implementations, one or more portions or components of theheating assembly 530 may be combined with, packaged with, and/orintegral with (e.g., embedded within) the aerosol precursor composition410. For example, in some implementations the aerosol precursorcomposition may be formed of a material as described above and mayinclude one or more conductive materials mixed therein. In some of theseimplementations, contacts may be connected directly to the aerosolprecursor composition such that, when the aerosol source member isinserted into the receiving chamber of the control body, the contactsmake electrical connection with the electrical energy source.Alternatively, the contacts may be integral with the electrical energysource and may extend into the receiving chamber such that, when theaerosol source member is inserted into the receiving chamber of thecontrol body, the contacts make electrical connection with the aerosolprecursor composition. Because of the presence of the conductivematerial in the aerosol precursor composition, the application of powerfrom the electrical energy source to the aerosol precursor compositionallows electrical current to flow and thus produce heat from theconductive material. Thus, in some implementations the heating elementmay be described as being integral with the aerosol precursorcomposition. As a non-limiting example, graphite or other suitable,conductive material may be mixed with, embedded in, or otherwise presentdirectly on or within the material forming the aerosol precursorcomposition to make the heating element integral with the medium.

As noted above, in the illustrated implementation, the outer cylinder532 may also serve to facilitate proper positioning of the aerosolsource member 304 when the aerosol source member is inserted into thehousing 516. In various implementations, the outer cylinder of theheating assembly 530 may engage an internal surface of the housing toprovide for alignment of the heating assembly with respect to thehousing. Thereby, as a result of the fixed coupling between the heatingassembly, a longitudinal axis of the heating assembly may extendsubstantially parallel to a longitudinal axis of the housing. Inparticular, the support cylinder may extend from the opening 518 of thehousing to the receiving base 536 to create the receiving chamber 538.

The heated end 406 of the aerosol source member 304 is sized and shapedfor insertion into the control body 302. In various implementations, thereceiving chamber 538 of the control body may be characterized as beingdefined by a wall with an inner surface and an outer surface, the innersurface defining the interior volume of the receiving chamber. Forexample, in the depicted implementations, the outer cylinder 532 definesan inner surface defining the interior volume of the receiving chamber.In the illustrated implementation, an inner diameter of the outercylinder may be slightly larger than or approximately equal to an outerdiameter of a corresponding aerosol source member (e.g., to create asliding fit) such that the outer cylinder is configured to guide theaerosol source member into the proper position (e.g., lateral position)with respect to the control body. Thus, the largest outer diameter (orother dimension depending upon the specific cross-sectional shape of theimplementations) of the aerosol source member may be sized to be lessthan the inner diameter (or other dimension) at the inner surface of thewall of the open end of the receiving chamber in the control body. Insome implementations, the difference in the respective diameters may besufficiently small so that the aerosol source member fits snugly intothe receiving chamber, and frictional forces prevent the aerosol sourcemember from being moved without an applied force. On the other hand, thedifference may be sufficient to allow the aerosol source member to slideinto or out of the receiving chamber without requiring undue force.

In the illustrated implementation, the control body 302 is configuredsuch that when the aerosol source member 304 is inserted into thecontrol body, the heating element 534 (e.g., heater prongs) is locatedin the approximate radial center of at least a portion of the aerosolprecursor composition 410 of the heated end 406 of the aerosol sourcemember. In such a manner, when used in conjunction with a solid orsemi-solid aerosol precursor composition, the heater prongs may be indirect contact with the aerosol precursor composition. In otherimplementations, such as when used in conjunction with an extrudedaerosol precursor composition that defines a tube structure, the heaterprongs may be located inside of a cavity defined by an inner surface ofthe extruded tube structure, and would not contact the inner surface ofthe extruded tube structure.

During use, the consumer initiates heating of the heating assembly 530,and in particular, the heating element 534 that is adjacent the aerosolprecursor composition 410 (or a specific layer thereof). Heating of theaerosol precursor composition releases the inhalable substance withinthe aerosol source member 304 so as to yield the inhalable substance.When the consumer inhales on the mouth end 408 of the aerosol sourcemember, air is drawn into the aerosol source member through an airintake 540 such as openings or apertures in the control body 302. Thecombination of the drawn air and the released inhalable substance isinhaled by the consumer as the drawn materials exit the mouth end of theaerosol source member. In some implementations, to initiate heating, theconsumer may manually actuate a pushbutton or similar component thatcauses the heating element of the heating assembly to receive electricalenergy from the battery or other energy source. The electrical energymay be supplied for a pre-determined length of time or may be manuallycontrolled.

In some implementations, flow of electrical energy does notsubstantially proceed in between puffs on the device 300 (althoughenergy flow may proceed to maintain a baseline temperature greater thanambient temperature—e.g., a temperature that facilitates rapid heatingto the active heating temperature). In the depicted implementation,however, heating is initiated by the puffing action of the consumerthrough use of one or more sensors, such as flow sensor 520. Once thepuff is discontinued, heating will stop or be reduced. When the consumerhas taken a sufficient number of puffs so as to have released asufficient amount of the inhalable substance (e.g., an amount sufficientto equate to a typical smoking experience), the aerosol source member304 may be removed from the control body 302 and discarded. In someimplementations, further sensing elements, such as capacitive sensingelements and other sensors, may be used as discussed in U.S. patentapplication Ser. No. 15/707,461 to Phillips et al., which isincorporated herein by reference.

In various implementations, the aerosol source member 304 may be formedof any material suitable for forming and maintaining an appropriateconformation, such as a tubular shape, and for retaining therein theaerosol precursor composition 410. In some implementations, the aerosolsource member may be formed of a single wall or, in otherimplementations, multiple walls, and may be formed of a material(natural or synthetic) that is heat resistant so as to retain itsstructural integrity—e.g., does not degrade—at least at a temperaturethat is the heating temperature provided by the electrical heatingelement, as further discussed herein. While in some implementations, aheat resistant polymer may be used, in other implementations, theaerosol source member may be formed from paper, such as a paper that issubstantially straw-shaped. As further discussed herein, the aerosolsource member may have one or more layers associated therewith thatfunction to substantially prevent movement of vapor therethrough. In oneexample implementation, an aluminum foil layer may be laminated to onesurface of the aerosol source member. Ceramic materials also may beused. In further implementations, an insulating material may be used soas not to unnecessarily move heat away from the aerosol precursorcomposition. Further example types of components and materials that maybe used to provide the functions described above or be used asalternatives to the materials and components noted above can be those ofthe types set forth in U.S. Pat. App. Pub. Nos. 2010/00186757 to Crookset al., 2010/00186757 to Crooks et al., and 2011/0041861 to Sebastian etal., all of which are incorporated herein by reference.

In the depicted implementation, the control body 302 includes a controlcomponent 522 that controls the various functions of the aerosoldelivery device 300, including providing power to the electrical heatingelement 534. For example, the control component may include processingcircuitry (which may be connected to further components, as furtherdescribed herein) that is connected by electrically conductive wires(not shown) to the power source 524. In various implementations, theprocessing circuitry may control when and how the heating assembly 530,and particularly the heater prongs, receives electrical energy to heatthe aerosol precursor composition 410 for release of the inhalablesubstance for inhalation by a consumer. In some implementations, suchcontrol may be activated by a flow sensor 520 as described in greaterdetail above.

As seen in FIGS. 5 and 6, the heating assembly 530 of the depictedimplementation comprises an outer cylinder 532 and a heating element 534(e.g., plurality of heater prongs) that extend from a receiving base536. In some implementations, such as those wherein the aerosolprecursor composition 410 comprises a tube structure, the heater prongsmay be configured to extend into a cavity defined by the inner surfaceof the aerosol precursor composition. In other implementations, such asthe depicted implementation wherein the aerosol precursor compositioncomprises a solid or semi-solid, the plurality of heater prongs areconfigured to penetrate into the aerosol precursor composition containedin the heated end 406 of the aerosol source member 304 when the aerosolsource member is inserted into the control body 302. In suchimplementations, one or more of the components of the heating assembly,including the heater prongs and/or the receiving base, may beconstructed of a non-stick or stick-resistant material, for example,certain aluminum, copper, stainless steel, carbon steel, and ceramicmaterials. In other implementations, one or more of the components ofthe heating assembly, including the heater prongs and/or the receivingbase, may include a non-stick coating, including, for example, apolytetrafluoroethylene (PTFE) coating, such as Teflon®, or othercoatings, such as a stick-resistant enamel coating, or a ceramiccoating, such as Greblon®, or Thermolon™, or a ceramic coating, such asGreblon®, or Thermolon™.

In addition, although in the depicted implementation there are multipleheater prongs 534 that are substantially equally distributed about thereceiving base 536, it should be noted that in other implementations,any number of heater prongs may be used, including as few as one, withany other suitable spatial configuration. Furthermore, in variousimplementations the length of the heater prongs may vary. For example,in some implementations the heater prongs may comprise smallprojections, while in other implementations the heater prongs may extendany portion of the length of the receiving chamber 538, including up toabout 25%, up to about 50%, up to about 75%, and up to about the fulllength of the receiving chamber. In still other implementations, theheating assembly 530 may take on other configurations. Examples of otherheater configurations that may be adapted for use in the presentinvention per the discussion provided above can be found in U.S. Pat.No. 5,060,671 to Counts et al., U.S. Pat. No. 5,093,894 to Deevi et al.,U.S. Pat. No. 5,224,498 to Deevi et al., U.S. Pat. No. 5,228,460 toSprinkel Jr., et al., U.S. Pat. No. 5,322,075 to Deevi et al., U.S. Pat.No. 5,353,813 to Deevi et al., U.S. Pat. No. 5,468,936 to Deevi et al.,U.S. Pat. No. 5,498,850 to Das, U.S. Pat. No. 5,659,656 to Das, U.S.Pat. No. 5,498,855 to Deevi et al., U.S. Pat. No. 5,530,225 toHajaligol, U.S. Pat. No. 5,665,262 to Hajaligol, U.S. Pat. No. 5,573,692to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhauer et al., whichare incorporated herein by reference.

In various implementations, the control body 302 may include an airintake 538 (e.g., one or more openings or apertures) therein forallowing entrance of ambient air into the interior of the receivingchamber 538. In such a manner, in some implementations the receivingbase 536 may also include an air intake. Thus, in some implementationswhen a consumer draws on the mouth end of the aerosol source member 304,air can be drawn through the air intake of the control body and thereceiving base into the receiving chamber, pass into the aerosol sourcemember, and be drawn through the aerosol precursor composition 410 ofthe aerosol source member for inhalation by the consumer. In someimplementations, the drawn air carries the inhalable substance throughthe optional filter 414 and out of an opening at the mouth end 408 ofthe aerosol source member. With the heating element 534 positionedinside the aerosol precursor composition, the heater prongs may beactivated to heat the aerosol precursor composition and cause release ofthe inhalable substance through the aerosol source member.

As described above with reference to FIGS. 5 and 6 in particular,various implementations of the present disclosure employ a conductiveheater to heat the aerosol precursor composition 410. As also indicatedabove, various other implementations employ an induction heater to heatthe aerosol precursor composition. In some of these implementations, theheating assembly 530 may be configured as an induction heater thatcomprises a transformer with an induction transmitter and an inductionreceiver. In implementations in which the heating assembly is configuredas the induction heater, the outer cylinder 532 may be configured as theinduction transmitter, and the heating element 534 (e.g., plurality ofheater prongs) that extend from the receiving base 536 may be configuredas the induction receiver. In various implementations, one or both ofthe induction transmitter and induction receiver may be located in thecontrol body 302 and/or the aerosol source member 304.

In various implementations, the outer cylinder 532 and heating element534 as the induction transmitter and induction receiver may beconstructed of one or more conductive materials, and in furtherimplementations the induction receiver may be constructed of aferromagnetic material including, but not limited to, cobalt, iron,nickel, and combinations thereof. In one example implementation, thefoil material is constructed of a conductive material and the heaterprongs are constructed of a ferromagnetic material. In variousimplementations, the receiving base may be constructed of anon-conductive and/or insulating material.

The outer cylinder 532 as the induction transmitter may include alaminate with a foil material that surrounds a support cylinder. In someimplementations, the foil material may include an electrical traceprinted thereon, such as, for example, one or more electrical tracesthat may, in some implementations, form a helical coil pattern when thefoil material is positioned around the heating element 534 as theinduction receiver. The foil material and support cylinder may eachdefine a tubular configuration. The support cylinder may be configuredto support the foil material such that the foil material does not moveinto contact with, and thereby short-circuit with, the heater prongs. Insuch a manner, the support cylinder may comprise a nonconductivematerial, which may be substantially transparent to an oscillatingmagnetic field produced by the foil material. In variousimplementations, the foil material may be imbedded in, or otherwisecoupled to, the support cylinder. In the illustrated implementation, thefoil material is engaged with an outer surface of the support cylinder;however, in other implementations, the foil material may be positionedat an inner surface of the support cylinder or be fully imbedded in thesupport cylinder.

The foil material of the outer cylinder 532 may be configured to createan oscillating magnetic field (e.g., a magnetic field that variesperiodically with time) when alternating current is directed through it.The heater prongs of the heating element 534 may be at least partiallylocated or received within the outer cylinder and include a conductivematerial. By directing alternating current through the foil material,eddy currents may be generated in the heater prongs via induction. Theeddy currents flowing through the resistance of the material definingthe heater prongs may heat it by Joule heating (i.e., through the Jouleeffect). The heater prongs may be wirelessly heated to form an aerosolfrom the aerosol precursor composition 410 positioned in proximity tothe heater prongs.

Other implementations of the aerosol delivery device, control body andaerosol source member are described in the above-cited U.S. patentapplication Ser. No. 15/916,834 to Sur et al., U.S. patent applicationSer. No. 15/916,696 to Sur, and U.S. patent application Ser. No.15/836,086 to Sur.

As described above, the aerosol delivery device of exampleimplementations may include circuitry in the context of either anelectronic cigarette or a heat-not-burn device, or even in the case of adevice that includes the functionality of both. FIGS. 7A and 7B arecircuit diagrams of an aerosol delivery device 700 that may be orincorporate functionality of either or both aerosol delivery devices100, 300 according to various example implementations of the presentdisclosure. As shown, the aerosol delivery device includes a controlbody 702, a heating element 704, power source 706 and charge circuitry708 that may correspond to or include functionality of respective onesof the control body 102, 302, heating element 222, 534, power source212, 524 and charge circuitry 216, 528. And in some examples such asthose in which the aerosol delivery device 700 is or incorporates thefunctionality of aerosol delivery device 100, the aerosol deliverydevice 700 (or more specifically its control body 702) may includeterminals 710 configured to connect the heating element to the controlbody.

In various implementations, the charge circuitry 708 is coupled to andconfigured to controllably charge the power source 706. The power sourceincludes one or more batteries or battery cells coupled to andconfigured to power a load 712 including the heating element 704 that isconfigured to convert electricity to heat and thereby vaporizecomponents of the aerosol precursor composition. In someimplementations, the one or more batteries or battery cells of the powersource include one or more lithium-ion, lithium iron phosphate or solidstate batteries or battery cells.

As shown in FIG. 7A, in some implementations, the charge circuitry 708includes an electrical connector 714, a protection circuit 716 and abuck-boost charge controller 718. The electrical connector is configuredto connect the charge circuitry to a power supply 720 from which thepower source 706 is chargeable, directly or indirectly such as via anappropriate power adapter. The electrical connector may be any of anumber of suitable types of electrical connectors such as thosedescribed above. In some implementations, the electrical connector is aUSB connector (e.g., Type A, Type B, Mini A, Mini B, Mini AB, Micro A,Micro B, Micro AB, Type C). In other implementations, the electricalconnector is a non-USB connector (e.g. cylindrical connector, cigarettelighter connector, Lightning connector). In these and otherimplementations, the power adapter may be a USB power adapter or anon-USB power adapter. And in other examples, the charge circuitry mayinclude an induction receiver in lieu of an electrical connector forinduction-powered charging.

In some examples, the charge circuitry 708 can support batteries orbattery cells with different electrochemistry such as lithium-ion orlithium iron phosphate. Also, the charge circuitry can provide a lowbattery quiescent current and have an instant on with no battery ordeeply discharged battery. In one example, the charge circuitry may havean over voltage when the power source is removed during the chargingprocess or the user plugs in the wrong battery or battery cell forcharging. The electronics in the charge circuitry may have amicrocontroller where the profile of the electrochemistry of the LithiumIon battery can be inserted. If a consumer plugs in a wrong lithiumbattery, then the profile of the wrong battery may not coincide with thestored profile in the microcontroller. Thus, the battery may take alonger time or shorter time to charge depending on what battery wasplugged in. Also the charging current can be fixed on a particularbattery. Thus if a different battery is used, the charging time may beincreased depending on the size of the battery being used. If the sizeof the battery is bigger, then the charging time may be longer. Also thecharger circuitry can cap the over voltage to a particular value. Thus,irrespective of what battery is plugged in, the over voltage conditionwill not be violated.

In some implementations, the protection circuit 716 is coupled to andbetween the electrical connector 714 and the power source 706. Theprotection circuit is configured to protect the power source from anovercurrent condition in the power supply 720 when the electricalconnector is coupled to the power supply. In some implementations, theprotection circuit includes a switch (as shown in FIG. 7B) configured tointerrupt the output current from the power supply to the power sourcewhen the power supply is in the overcurrent condition.

In some implementations, the buck-boost charge controller 718 is coupledto and between the power source 706 and the power supply 720. Thebuck-boost charge controller is configured to regulate output voltageand output current from the power supply to the power source,selectively in one of a plurality of modes based on a condition of thepower supply. In some implementations, the plurality of modes includestwo or more of a buck mode, a boost mode or a buck-boost mode. Oneexample of a suitable buck-boost charge controller is the model BQ25703Afrom Texas Instruments. During the power up of the aerosol deliverydevice 700, the buck-boost charge controller may set converter to buck,boost or buck boost mode based on a condition of the power supply. Thebuck-boost charge controller may automatically transit among buck, boostand buck boost modes without host control.

In some implementations, a boost circuitry can be used to increase thevoltage artificially to a certain value for the circuitry to work. Forexample, if the voltage goes down to 3.1V, with a boost chip the voltagecan be boosted to 3.5 V for the rest of the circuitry to work. For aboost circuitry, the boost regulator can operate from a smaller voltagesuch as from 2.7V to 3.5V to provide a higher nominal voltage capped at3.5V. In a boost circuitry, there can be a feedback compensation toensure that the voltage is always at a constant value. The buckconverter may have an integrated step down switching regulator using ahysteretic (or materials showing hysteresis properties) and a step downDC-DC converter. The buck converter can change the voltage of a fullycharged battery from 4.1V to a constant voltage of 3.5V, which canprovide better efficiency of the battery. The buck-boost circuitry maybe a combination of the buck and boost described above and can performthe dual function of both buck and boost.

In some implementations, the power supply 720 includes one or morelithium-ion or solid state batteries, or lithium-ion or hybridlithium-ion capacitors, and the buck-boost charge controller 718 isconfigured to regulate the output voltage and output current from theone or more lithium-ion or solid state batteries, or lithium-ion orhybrid lithium-ion capacitors of the power supply. In someimplementations, the buck-boost charge controller is configured to limitthe output current to a maximum current (e.g., 380 mA) when a terminalvoltage of the power source 706 falls below a threshold voltage when thepower source is charged from the power supply.

FIG. 7B illustrates a circuit diagram of the aerosol delivery device 700according to various example implementations of the present disclosure.As shown, the aerosol delivery device includes a control body 702, aheating element 704, power source 706 and charge circuitry 708. Thecharge circuitry is coupled to and configured to controllably charge thepower source. Similarly as in FIG. 7A, the charge circuitry includes anelectrical connector 714, a protection circuit 716 and a buck-boostcharge controller 718. The charge circuitry may also include an I/Ointerface 738 (e.g., an inter-integrated circuit interface) coupled tothe buck-boost charge controller. The I/O interface may give theflexibility for the user to change the charging current or limit thecharging current to a certain value depending on the battery orcapacitor being charged. For example, for a particular lithium ionbattery, a supercapacitor or a lithium ion hybrid capacitor beingcharged, the charging current may be 1 C, 2 C or 5 C charge rate. TheI/O interface can limit the charging current to a particular valuedepending on the maximum rating on the battery, supercapacitor or hybridlithium ion capacitor. Thus the electronic design may be robust enoughto support a variety of lithium ion battery, supercapacitor, hybridlithium ion capacitor or solid state battery. In one example, a user canset specific values or select type of power source via the I/Ointerface. In another example, the charge circuitry can selectappropriate values from pre-stored correlation between type andvalue(s), e.g., from a lookup table.

In some implementations, the protection circuit 716 includes one or moretransistors 722, 724, 726 and 728 used as one or more switchesconfigured to interrupt the output current from the power supply 720 tothe power source 706 when the power supply is in the overcurrentcondition. The transistors may be metal-oxide-semiconductor field-effecttransistors (MOSFETs). One example of a suitable MOSFET includes themodel 2N6659 from Motorola.

In some implementations, the power source 706 includes a plurality ofbatteries or battery cells 730, 732, 734 and 736. The plurality ofbatteries or battery cells are connected to form two or more paths forthe output current from the power supply 720 to flow through such thatthe output current is a sum of currents through each path of theplurality of paths. In one example, the output current from power supplycan be 6.35A. In this example, the four batteries as shown in FIG. 7Bmay be connected to form two paths for the output current, with a pairof the batteries on each path. The 6.35A may be split between the twopaths with each pair of batteries being supplied 3.175A for fastcharging. In this way, the four batteries can be charged faster. Inanother example, the four batteries may be connected to form four pathsfor the output current, with one of the four batteries on each path.

In some implementations, the aerosol delivery device 700 or the controlbody 702 further includes a non-inverting unity gain operationalamplifier 740 coupled to the heating element 704 and configured tooutput a constant power to the load 712 or the heating element. Theoutput power to the load or the heating element can be constantirrespective of any parasitics in the circuit board (e.g., printedcircuit board) due to traces or other reasons. Also the non-invertingunity gain operational amplifier can nullify the antenna effect of anydiscrete components in the aerosol delivery device.

Many modifications and other implementations of the disclosure will cometo mind to one skilled in the art to which this disclosure pertainshaving the benefit of the teachings presented in the foregoingdescriptions and the associated drawings. Therefore, it is to beunderstood that the disclosure is not to be limited to the specificimplementations disclosed herein and that modifications and otherimplementations are intended to be included within the scope of theappended claims. Although specific terms are employed herein, they areused in a generic and descriptive sense only and not for purposes oflimitation.

What is claimed is:
 1. An aerosol delivery device comprising: a housing structured to retain an aerosol precursor composition; a heating element configured to convert electricity to heat and thereby vaporize components of the aerosol precursor composition; a power source including one or more batteries or battery cells coupled to and configured to power a load including the heating element; and charge circuitry coupled to and configured to controllably charge the power source, the charge circuitry including: an electrical connector configured to connect the charge circuitry to a power supply from which the power source is chargeable; and a buck-boost charge controller coupled to and between the power source and power supply, and configured to regulate output voltage and output current from the power supply to the power source, selectively in one of a plurality of modes based on a condition of the power supply.
 2. The aerosol delivery device of claim 1, wherein the power source includes a plurality of batteries or battery cells.
 3. The aerosol delivery device of claim 2, wherein the plurality of batteries or battery cells are connected to form a plurality of paths for the output current from the power supply to flow through such that the output current is a sum of currents through each path of the plurality of paths.
 4. The aerosol delivery device of claim 1, wherein the one or more batteries or battery cells include one or more lithium-ion, lithium iron phosphate or solid-state batteries or battery cells.
 5. The aerosol delivery device of claim 1, wherein the power supply includes one or more lithium-ion or solid-state batteries, or lithium-ion or hybrid lithium-ion capacitors, and the buck-boost charge controller being configured to regulate the output voltage and output current from the power supply includes being configured to regulate the output voltage and output current from the one or more lithium-ion or solid-state batteries, or lithium-ion or hybrid lithium-ion capacitors.
 6. The aerosol delivery device of claim 1, wherein the charge circuitry further includes a protection circuit coupled to and between the electrical connector and the power source, and configured to protect the power source from an overcurrent condition in the power supply when the electrical connector is coupled to the power supply.
 7. The aerosol delivery device of claim 6, wherein the protection circuit includes a switch configured to interrupt the output current from the power supply to the power source when the power supply is in the overcurrent condition.
 8. The aerosol delivery device of claim 1, wherein the buck-boost charge controller being configured to regulate the output voltage and output current includes being configured to limit the output current to a maximum current when a terminal voltage of the power source falls below a threshold voltage when the power source is charged from the power supply.
 9. The aerosol delivery device of claim 1, wherein the aerosol precursor composition is a liquid, or a solid or semi-solid.
 10. The aerosol delivery device of claim 1, further comprising a non-inverting unity gain operational amplifier coupled to the heating element and configured to output a constant power to the heating element.
 11. The aerosol delivery device of claim 1, wherein the plurality of modes includes two or more of a buck mode, a boost mode or a buck-boost mode.
 12. A control body for an aerosol delivery device, the control body comprising: a heating element or terminals configured to connect the heating element to the control body, the heating element being configured to convert electricity to heat and thereby vaporize components of an aerosol precursor composition; a power source including one or more batteries or battery cells coupled to and configured to power a load including the heating element; and charge circuitry coupled to and configured to controllably charge the power source, the charge circuitry including: an electrical connector configured to connect the charge circuitry to a power supply from which the power source is chargeable; and a buck-boost charge controller coupled to and between the power source and power supply, and configured to regulate output voltage and output current from the power supply to the power source, selectively in one of a plurality of modes based on a condition of the power supply.
 13. The control body of claim 12, wherein the power source includes a plurality of batteries or battery cells.
 14. The control body of claim 13, wherein the plurality of batteries or battery cells are connected to form a plurality of paths for the output current from the power supply to flow through such that the output current is a sum of currents through each path of the plurality of paths.
 15. The control body of claim 12, wherein the one or more batteries or battery cells include one or more lithium-ion, lithium iron phosphate or solid-state batteries or battery cells.
 16. The control body of claim 12, wherein the power supply includes one or more lithium-ion or solid-state batteries, or lithium-ion or hybrid lithium-ion capacitors, and the buck-boost charge controller being configured to regulate the output voltage and output current from the power supply includes being configured to regulate the output voltage and output current from the one or more lithium-ion or solid-state batteries, or lithium-ion or hybrid lithium-ion capacitors.
 17. The control body of claim 12, wherein the charge circuitry further includes a protection circuit coupled to and between the electrical connector and the power source, and configured to protect the power source from an overcurrent condition in the power supply when the electrical connector is coupled to the power supply.
 18. The control body of claim 17, wherein the protection circuit includes a switch configured to interrupt the output current from the power supply to the power source when the power supply is in the overcurrent condition.
 19. The control body of claim 12, wherein the buck-boost charge controller being configured to regulate the output voltage and output current includes being configured to limit the output current to a maximum current when a terminal voltage of the power source falls below a threshold voltage when the power source is charged from the power supply.
 20. The control body of claim 12, wherein the aerosol precursor composition is a liquid, or a solid or semi-solid.
 21. The control body of claim 12, further comprising a non-inverting unity gain operational amplifier coupled to the heating element and configured to output a constant power to the heating element.
 22. The control body of claim 12, wherein the plurality of modes includes two or more of a buck mode, a boost mode or a buck-boost mode. 